The Controls Engineer is responsible for the design, development, programming, implementation, and support of industrial automation systems for custom machinery and manufacturing equipment. This position will design electrical control systems, develop PLC and HMI software, support machine commissioning, troubleshoot production equipment, and provide technical support for manufacturing operations.
The Controls Engineer will work closely with engineering, manufacturing, maintenance, and customers to develop reliable automation solutions that meet performance, quality, and productivity requirements. This role requires strong technical knowledge of industrial controls, motion systems, industrial networking, and machine design principles.
Essential Duties and Responsibilities
Controls System Design
- Design electrical control systems for custom machinery and automation equipment.
- Develop complete control panel layouts, electrical schematics, wiring diagrams, and bills of materials.
- Create and maintain electrical drawings using AutoCAD Electrical.
- Select and size electrical components including drives, motors, servos, safety devices, sensors, and control hardware.
- Ensure compliance with applicable electrical and machine safety standards.
PLC and HMI Programming
- Develop, modify, test, and support PLC programs primarily using Allen-Bradley software platforms.
- Create and maintain programs utilizing Studio 5000 and other Allen-Bradley software applications.
- Troubleshoot, optimize, and improve existing machine control systems.
- Develop and maintain HMI applications using Allen-Bradley and C-More platforms.
- Design operator-friendly graphical interfaces and machine displays.
- Modify and develop graphics using Adobe Photoshop or equivalent software for HMI applications.
Motion Control and Automation
- Configure and troubleshoot servo systems, frequency drives (VFDs), encoders, and motion control applications.
- Develop and support machine sequencing and coordinated motion systems.
- Assist with machine startup, commissioning, and validation activities.
- Support troubleshooting of electrical, controls, and motion-related issues.
CNC and Manufacturing Support
- Maintain a working knowledge of CNC machine controls and machine operation.
- Assist with troubleshooting CNC-related equipment and automation interfaces.
- Provide controls support for manufacturing operations and process improvements.
- Support laser and turret equipment troubleshooting as needed.
- Serve as a technical resource for maintenance and production teams.
Software Development and Integration
- Develop and support manufacturing applications utilizing Microsoft Visual Studio.
- Integrate business systems, databases, and PLC platforms.
- Support database development and communication between automation systems and software applications.
- Maintain and troubleshoot industrial networking infrastructure including Ethernet/IP and related industrial communication protocols.
Project Engineering
- Perform machine cycle-time analysis and production time studies.
- Evaluate equipment capabilities to ensure customer production requirements are achieved.
- Develop concepts and control system solutions for internal and external customers.
- Generate cost estimates, control system budgets, and project quotations.
- Present technical solutions and project proposals to customers and management.
- Support project scheduling and execution from concept through installation.
Qualifications
Required
- Bachelor's Degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, Automation Engineering, or related field.
- Equivalent combination of education and hands-on industrial controls experience may be considered.
- Minimum 3-5 years of industrial controls or automation experience preferred.
- Experience designing industrial electrical control systems.
- Experience developing PLC and HMI software.
- Strong troubleshooting and problem-solving skills.
- Ability to manage multiple projects and priorities.
Preferred
- Experience with custom machine building.
- Experience with machine commissioning and startup.
- Experience with motion control applications.
- Experience with CNC equipment and controls.
- Experience with database integration and software development.
- Knowledge of manufacturing processes and industrial automation systems.
Physical Requirements
- Ability to work in both office and manufacturing environments.
- Ability to stand, walk, bend, and climb equipment as needed during troubleshooting and commissioning activities.
- Ability to occasionally lift up to 50 pounds.
- Ability to travel occasionally to customer or company facilities as required.
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